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Veriforce – TG CCT 661OP
TG Common Covered Task 661OP Rev. # 4 Page 1 of 12 Copyright © 2017 Veriforce, LLC. All rights reserved. 11/08/2017
Directions: This training guide is to be used by a Veriforce Authorized Evaluator/Trainer and Trainee during on-the-
job training (OJT) or prior to an evaluation as a resource. (S) Indicates a demonstration or skill task; (K) indicates a
knowledge task.
OJT Reminder: OJT is an active hands-on process. Practice should be as similar to the actual job task as possible.
However, if the training is being provided on an actual job site while a covered task is actually being performed, the
Evaluator either needs to be qualified on that covered task or be assisted by someone who is qualified on the
covered task. The Evaluator should closely monitor the Trainee's practices to ensure safe and correct task
performance. At no time should a non-qualified individual perform, or train for, a covered task unless directed and
observed by a qualified individual. However, if the “span of control” for that particular covered task is “1:0” (requiring
only qualified individuals to perform the covered task), the training must be simulated. Training is simulated by
"walking through" the task and simulating all actual manipulations (valves, switches, tools, etc.) an individual would
use during the performance of a covered task. Simulating includes the use of safety and administrative requirements
as if the task were being performed live. Refer to the Veriforce Evaluator Training Program for more on how to
conduct formal OJT.
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Training Guide
CCT: 661OP Launching and/or Receiving Internal Devices (Pigs)
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Recommended Student Training or Resources:
Recommended Student Training or Resources:
DOT 49 CFR 192.476 DOT 49 CFR 192.620(d)(5)(iv) DOT 49 CFR 192.620(d)(9) DOT 49 CFR 192.937(c) DOT 49 CFR 195.426
Internal Devices (Pigs)
Internal devices also known as pigs are used to preform several maintenance tasks to the pipeline. These
tasks can take place during pipeline construction to pipeline decommission. Some of the tasks include:
Clean the inside of the pipeline
Conduct maintenance
Separate product (batching)
Remove blockages inside the pipeline
Before a pig can be introduced into a line, there are certain steps that need to be followed. Pipelines are
often operating at high pressures and can pose serious hazards if an pig is introduced or removed
incorrectly. Your ability to properly perform this task will help maintain the integrity of the pipeline and,
more importantly, the safety of you and your co-workers.
Knowledge Explain what is required prior to performing task.
Prior to performing this task, you will need the:
Pipeline operator-approved procedures for the specific site
Appropriate equipment/materials needed
Type of pig needed to preform the operator specific task
Pipeline Operator-Approved Procedures
The Operator will develop site-specific procedures for each pigging site. The procedure will typically
include:
The normal procedure for launching and receiving
Safety concerns of the site.
The Normal Procedure for Launching and Receiving
Procedures will vary from Operator to Operator, but the majority of procedures will include information
such as launcher or receiver layout, diagrams, and the sequence of valves for launching and receiving.
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Safety Concerns of the Site
The Operator’s procedure could also address safety concerns that must be addressed before performing
the task, such as the type of product in the line as well as the site specific hazards that might be seen on
the site.
Perhaps the most important condition that must be maintained is the flow on the pipeline. A blockage can
cause over pressure that could result in rupture.
Some other safety concerns include, but are not limited to:
Venting or releasing of product
Actions to take for a stuck pig
Proper procedures should be followed for venting or draining of explosive gases.
Should you have any questions regarding the Operator procedure and safety concerns, please notify your
supervisor or operator representative.
Appropriate Equipment/Materials
When performing pigging operations, it is important that only the appropriate equipment or materials are
used in the process.
Each site will have specific instructions on how the work should be performed.
Factors that could affect the equipment or material needed could be:
The type of product in the pipeline
What will be used to propel the pig, such as:
product flow
compressed air
or nitrogen
Depending on the size of the pig being launched, special equipment might be required to load and launch.
Device (Scraper, Sphere, Brush)
To perform this task, you will need a pig. There are many types of pigs and each type has a different use.
Some of the most common types include:
Scraper – which is used to scrape the inside walls of the pipeline to remove debris, left over
product, or built-up material.
Sphere - which can be of a solid construction or filled with glycol or water.
Brush – which is used for light to medium cleaning of the pipeline.
ILI (In-line inspection tools), also known as smart pigs, - which can be used to provide information
on the internal condition of the pipe.
Make sure to compare the information that you received in the pipeline diagram to the pig manufacturer
specifications.
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Tools, Gaskets, Pressure Gauges, Gas Monitors
In addition to the pig, you will also need a variety of tools and equipment. These include, but are not
limited to:
Pipe wrenches
Gaskets
Pressure gauges
Gas monitors
Fire fighting equipment
Personal Protective Equipment (PPE)
Forklift or crane
Waste recovery equipment
Hydraulic rams or winches
Knowledge Explain how to verify the condition of the device to be launched.
Prior to performing this task, you will need to verify the condition of the pig to be launched. This is done to
make sure the size, type, material, and condition of the pig meet operator requirements. You can
determine the correct pig to use through the following process.
Size
Inspect the pig for correct sizing. The size of the pig should not be more than 90 percent of the diameter
of the smallest part of the pipeline that is to be pigged. This includes all valves and bends.
A pipe diagram should be obtained through the pipeline operator that shows the size of the bends in the
pipeline.
Compare the information that you received in the pipeline diagram to the pig manufacturer’s
specifications. If there are valves that reduce or restrict the pipeline, it is possible the line is not able to be
pigged.
Type
Next, you should check that the pig is the correct type.
The type of pig will depend on the operation that the Operator has requested to be completed.
Examples include:
Cleaning
Inspecting
Drying
Batching
Using the correct pig is important. Using the wrong pig can damage the pig, the pipeline, or cause the pig
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to become stuck in the pipeline.
Material
The material the pig is constructed of is also an important factor to consider.
Some of the common materials include:
Gel
Polyurethane
Foam
When deciding what pig to use make sure it works with what is flowing through the pipe. Doing this will
avoid damaging the pig or affecting the product flowing through the pipe.
Before launching any pig, you should check the body of the pig to be launched and ensure that it is in
good condition and has no broken parts or excessive wear.
Refer to your Operator’s guidelines to verify the type of pig that is needed.
Knowledge Launcher and Receiver Components
Main Pipeline Valve
The main pipeline valve is used to isolate the pig launcher from the mainline.
Main Bypass Valve
The main bypass valve is used to redirect the flow around the pig launcher.
Bypass Valve
The bypass valve can be used to move the flow from in front of the pig to behind the pig. This can also be
known as a bridal valve.
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Drain Valve
The drain valve or sump is used to remove any type of liquid from the line. It typically connects to a
recovery unit that collects the drained liquid.
Blowdown Valve
The blow down valve is used to remove any pressure from the isolated part of the line. Some launchers
may have more than one blow down valve.
Main Line Blowdown Valve
The main line blow down valve may be used to lower the pressure on the receiver end to allow the pig to
arrive at the receiver.
Closure Door
The closure door is the entry and exit point for the pig. There are several different types of closures. Two
common types you might see are the hinged type and the screw type.
Pressure Indicator
The Pressure Indicator can be any type of device that visually shows you that pressure still remains on
the pipe.
It may consist of:
Digital pressure gauges
Manual pressure gauges
Closure pressure alert valve (also known as a tattle tale)
Barrel
The Barrel is the larger part of the launcher. The added space provides the room needed to easily load
and remove the pig from the launcher. The barrel runs from the launcher closure to the reducer.
Thermal Relief Valve
The Thermal Relief Valve works just like a normal relief valve but operates off temperature. If the
temperature rises above the preset temperature, the valve opens, removing the pressure.
Reducer
The Reducer brings the size of the pipe from the launcher to the normal size of the pipe.
Pup
A Pup is a short length of pipe that is used in between the valve and the end of the launcher. The real use
for a Pup is to spread out the heat-affected zone from welding the pipeline together.
Pig Signal Indicator
A Pig Signal Indicator is a manual device that can be attached to the pig launcher that will notify you once
the pig has passed the signal.
Note: If a manual pig sig is not attached to the launcher or receiver, you may need to listen or feel
the vibration to track the pig as it is launched or received.
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Note: Refer to your Operator-specific guidelines for the type of method used to track the pig being
launched or received.
Vent Valve
The Vent Valve may be present on some units to allow a second place to vent the pressure from the
receiver. This second valve will show you that no pressure is built up behind the pig in the receiver.
Barred Tee
The Barred Tee is used inside the pipeline to ensure that the pig does not go the wrong way in the
pipeline.
Skill Demonstrate how to perform a launching operation.
Now, that you have read bit about what the pig does for the pipeline, let’s talk about how to perform a
launching operation.
Note: The process that we are discussing is for a specific site. Each site may have different
process steps or different equipment. Before conducting pigging operations, refer to your
Operator’s site specific procedures and review the piping diagram.
First, take a look at your site. Ensure that all necessary personal protective equipment (PPE) is available
and properly worn. PPE requirements may differ for each location; therefore, follow Operator guidelines.
As soon as you are on site, begin to monitor the atmosphere with gas monitors to ensure that there are no
explosive conditions present. Monitoring will continue until you are finished and leave the site. Also, look
around for any visual safety issues or physical defects on the pipeline. The launcher area should be free
of any extra materials that will not be used in the process. Once you are sure you have a hazard-free
work site, the next step is to perform the launching operation.
The following steps will be used to perform the launching operation:
Identify and locate associated valves for launching operation
Ensure valves function correctly and are operated in the proper sequence for launching phases
Remove the product/gas from the launcher and associated isolated piping
Ensure that no pressure exists in the barrel before opening the barrel door
Verify the pig is loaded correctly
Purge and/or pressurize the piping in preparation for launching
Place valves in correct position for launching the pig and launch into the piping system
Verify all identified valves are realigned for normal configuration
Identify and locate associated valves for launching operation.
Start by identifying the associated valves for the launching operation. The site diagram you received from
the operator should tell you the correct valves in the order in which they need to be operated. If no
pipeline diagram is available, contact your Operator representative for assistance. This is necessary
because every site may be setup differently.
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Ensure valves function correctly and are operated in the proper sequence for launching phases.
When preparing for a launching operation the main objective is to maintain the flow at all times.
If the flow is not maintained, the over pressure could cause injury or damage to the pipeline.
Over pressure can be prevented by ensuring the valves function correctly and are operated in proper
sequence for launching phases.
A method recommend by best practices is that a dry run of the operation be conducted before working on
an active pipeline.
The dry run should cover the process step by step as well as emergency procedures that the workers
may need to perform.
The valves that will be used in the process should be tested prior to conducting the launch operation to
ensure they open and close fully.
Remove the product/gas from the launcher and associated isolated piping.
Once you have located and closed the correct valves to isolate the launcher, the pressure will have to be
removed from the launcher.
Note: DO NOT STAND DIRECTLY IN FRONT OF THE LAUNCHER OR RECEIVER CLOSURE
DOOR. Pressure can build up behind a blockage, and once the blockage is removed, the
pressure will push out the closure door.
Different methods can be used to release the pressure from the launcher.
Common methods are venting, draining, purging, and flaring the product.
Note: Precautions need to be taken so that product is not released into the atmosphere. If the
pipeline is running a liquid, Nitrogen may be used to purge the launching barrel.
Refer to the Operator-specific guidelines for what method will be used.
Ensure that no pressure exists in the barrel before opening barrel door.
Now, that you have vented the pressure from the launcher, we must verify that all pressure has been
removed. The process will be determined by the equipment being used. Several methods may be used
to determine pressure build up. A couple of these methods could involve the use of :
Gauges
Closure pressure alert valve (which can also be referred to as a tattle tale)
Note: Before conducting any type of pressure release, ensure that all ignition sources have been
removed from the area.
Verify device is loaded correctly.
Now that the pressure has been released from the launcher, we can open the launcher closure.
You may see many different types of launcher closures. Two commonly used types are:
Screw end cap
Breach type
When loading the pig, it is important to stand off to the side of the launcher door. Do not stand in the line
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of fire.
The specific pigs may have different loading procedures such as the need for a crane or fork lift for the
larger pigs. Refer to the manufacturer’s instructions and the Operator’s procedures for loading
instructions.
The key to look out for is to ensure that the rear of the pig is past the inlet of the launcher. In order to do
this, some special equipment may be needed such as a push bar or hydraulic ram.
Purge and/or pressurize the piping in preparation for launching.
Now that the pig is loaded, the closure door can be closed. Next, you can purge and/or pressurize the
piping in preparation for launching.
Different sites may have different procedures for pressurizing the line.
The key is to remove any unwanted gas from the launcher while adding the material that will be used to
push the pig.
One method for doing this is to seal the launcher door.
Then add the media that will be used to push the pig while leaving the vent line open. This is known as
line packing.
Once the pressure can be seen at the vent valve, close the vent.
Refer to your Operator instructions for the method to be used for your site.
Place valves in correct position for launching the device and launch into piping system.
Once the line has been pressurized, it will be necessary to place valves in the correct position for
launching the pig into the piping system.
This can be done by removing the isolation from the launcher and adding the media behind the pig.
Once the pig has been launched, it is necessary to verify that it has left the launcher.
There are several methods that can be used that include, but are not limited to:
Pig Sig- or a pig signal system
Visual observation- where you open the launcher to see if the pig has launched
Note: When using the visual method, ensure that the proper steps for opening the closure door have
been followed.
Verify all identified valves are realigned for normal configuration.
The Operator procedures will instruct you on how to place the valves once the operation is complete.
Using the Operator-approved setting for all valves, you must verify all identified valves are realigned for
normal configuration.
Refer to your Operator diagram and operating procedure for steps to take.
Skill Demonstrate how to perform a receiving operation
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Now that you have an understanding of how to launch a pig, let’s talk about how to perform a receiving
operation.
First, identify and locate the associated valves for the receiving operation.
After you have identified and located the valves for the receiving operation, make sure the valves are
functioning correctly. Follow the Operator’s operating instructions for proper sequence and receiving
pressures to be used.
Next, verify that the pig is received correctly.
You can view the pig sig markers to see if they have tripped. Ensure both pig sigs have tripped showing
the pig is fully in the receiver.
If a pig sig is not available, you can use a compass to find the front of the pig.
Note: This method will only work for pigs that have magnets located in the front of the pig.
Remove the product from the receiver and associated piping.
Note: Before opening the receiver, ensure that all pressure has been removed from the barrel.
Trapped pressure can push out past the pig with enough force to turn over a large front end
loader.
Once you’ve ensured that no pressure exists in the barrel, you can open the door and start the unloading
procedure. Verify unloading is completed correctly following all Operator instructions. Some key areas to
consider are:
The use of a tool puller to pull the pig from the receiver
Additional PPE might be required on the receiver site
Hazardous waste containment and NORM handling should be addressed
Once the pig has been unloaded correctly, the receiver and piping should be purged to remove any
potential hazardous conditions. Lastly, verify that all valves are realigned for normal configuration.
Candidates are required to possess the ability to RECOGNIZE and REACT to the listed AOCs for each
task. Be prepared to answer questions concerning additional AOCs that may be relevant. Evaluators may
ask questions about AOCs throughout the evaluation.
An AOC is defined in 49 CFR §§ 192.803 and 195.503 as:
A condition identified by the operator that may indicate a malfunction of a component or deviation
from normal operations that may:
Indicate a condition exceeding design limits; or
Result in a hazard(s) to persons, property, or the environment.
AOC
Recognize:
Unintentional release, vapors, or hazardous atmosphere could be signs that an abnormal operating condition has occurred. Examples could include, but are not limited to:
Blowing Gas
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Puddles
Dead Vegetation
Vapors from casing vents
React/Respond:
Proper responses to take in the event of unintentional release, vapors, or hazardous atmosphere included the following:
Eliminate potential ignition sources.
Move to a safe location.
Notify emergency response personnel, as appropriate.
Limit access to the location, as necessary.
Follow appropriate procedures for notification, documentation, and remedial action.
AOC
Recognize:
Material defects, anomalies, or physical damage of pipe or a component that have
impaired or are likely to impair the serviceability of the pipeline are abnormal operating
conditions. Examples include, but are not limited to:
Coupling defects
Exposed pipeline
Dents, and Gouges
React/Respond:
Proper reactions/responses to take in the event of material defects, anomalies, or
physical damage of pipe or a component that have impaired or are likely to impair the
serviceability of the pipeline include the following:
Determine the extent, cause and potential hazard(s) of the defect, anomaly, and/or damage.
Mark the location so it may be easily located, as appropriate.
Follow appropriate procedures for notification, documentation, and remedial action.
AOC
Recognize:
Failure or malfunction of pipeline components is an abnormal operating condition. Examples could include, but are not limited to:
Valve leaking
Internal device stuck
Pressure indicating device malfunction
Launcher door safety devices fail
React/Respond:
Proper reactions/responses to take in the event of a failure or malfunction of pipeline
component(s) include the following:
Determine the extent, cause and potential hazard(s) of the defect, anomaly,
and/or damage.
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Follow appropriate procedures for notification, documentation, and remedial action.
Glossary
Abnormal Operating Condition
A condition identified by the operator that may indicate a
malfunction of a component or deviation from normal
operations that may indicate a condition exceeding design
limits or result in a hazard(s) to persons, property, or the
environment.